Recyclable bituminous roofing material

ABSTRACT

Roofing material which is formed by one or more bituminous layers and is also provided with a liner and/or reinforcement.

BACKGROUND OF THE INVENTION

The present innovation pertains to roofing material which is formed ofor more bituminous layers and is also provided with a plastics linerand/or a reinforcement, more particularly of plastic and/or glass.

A roofing material of this kind is known.

In the case of known roofing material, the liner and/or reinforcement isformed, for example, by a nonwoven polyester web and/or glass web,respectively a woven fabric or cloth, or else of a combination of thesematerials. It is passed through a bath of melted bituminous material,with the bituminous material depositing on the opposite sides on and/orin the liner or reinforcement, and forming a coating.

In the case of known roofing material, the liner and/or reinforcementnecessarily has a melting point which is considerably higher than thetemperature of the bituminous coating bath, of around 180° C., throughwhich it is conveyed with a corresponding expenditure of force.

In order to be able to process bitumen into a bituminous roofingmembrane, it must be liquid. When bitumen is heated to meltingtemperature, to 50° C. or 60° C., for example, it becomes soft. It istherefore not liquid and not yet suitable for processing in a roofingmembrane.

In the case of the materials which are generally utilized for theliners, the situation is different. On reaching the melting temperature,these materials turn almost immediately into a liquid form. One of thereasons for this is that their mass is too low, which is for example at100 g/m².

The temperature at which the bitumen becomes liquid (in other words theprocessing temperature) is dependent on the nature of the bitumen. Iffiller and modifier are added to the bitumen and the bitumen ismodified, a bituminous mass is formed, in other words a bitumen compoundhaving a high viscosity. With a modified bitumen of this kind and hencea bitumen compound with numerous additions (fillers, modifier), it isnecessary, in order ultimately to give the bitumen compound a liquidform, to hold the processing temperature higher—at 200° C., for example.If only a few additions are present, the bitumen compound may already beliquid at a lower temperature, such as at 100° C. The processingtemperature of the corresponding bitumen grade is therefore 100° C.

The melting point of the plastics liner is usually about 250° C., as isthe case for the nonwoven polyester web that is often utilized. Thebituminous coating bath usually possesses a processing temperature ofaround 180° C.

The lifetime of the bituminous roofing material runs to about 25 to 30years, after which, for example, cracking occurs or the roof coveringmust be taken down for other reasons. Within this period, the bituminousconstituents remain almost intact and are outstandingly suitable,accordingly, for recycling. Since the roofing material wastes, however,contain not only bitumen and bitumen mixture but also the material ofthe liners and/or reinforcement, the material is often incinerated. Thishas very detrimental consequences for the environment, and leads to ahigh level of CO₂ emission. There is in fact a method known by which theroofing material wastes are recycled, by heating them and recovering themelted bitumen, although even with that method it remains necessary toincinerate the remaining wastes of the liners or reinforcement.

The object of the present innovation is therefore to counteract thesedisadvantages of the known roofing material.

SUMMARY OF THE INVENTION

In principle the liner and/or reinforcement may consist (almost)exclusively of a material having a melting temperature which correspondsto or is below that of the bituminous layer(s).

In a first aspect of the invention, the newly developed roofing materialhas the feature that the liner and/or reinforcement consists exclusively(or at least near-exclusively) of a material having a meltingtemperature which is higher than the melting temperature of thebituminous layer or layers and corresponds more or less to theprocessing temperature of the bituminous layer or layers.

A liner may consist, among other materials, of a plastics nonwoven(non-woven fabric, evidently nonwoven web), a woven fabric, or a cloth.

On the basis of a further feature of the roofing material correspondingto this innovation, the liner and/or reinforcement consists (almost)exclusively of a material having a melting temperature which correspondsto or is below that of the bituminous layer(s) or which corresponds toor is below the processing temperature of the bituminous layer orlayers.

A further feature of the newly developed roofing material is that theliner and/or reinforcement is formed (almost) exclusively of a materialhaving a melting temperature which is between 50° C. and 220° C., moreprecisely between 100° C. and 200° C.

A further feature of the newly developed roofing material is that theliner and/or reinforcement consists (almost) exclusively of a materialhaving a melting temperature which corresponds to or is below 180° C.

A further feature of the newly developed roofing material is that thereinforcement is formed by fibers and/or wires.

A further feature of the newly developed roofing material is that theliner is composed of one or more kinds of plastics polypropylene,polyamide (nylon), polyethene, polyethylene, polyvinyl chloride (PVC),polyacrylonitrile (acrylic), ethylene-vinyl acetate (EVA), and suchmaterials.

In accordance with this innovation, the liner consists (almost)exclusively of one or more of the stated materials. The newly developedroofing material contains (almost) no materials whose meltingtemperature is substantially higher than the processing temperature ofthe bitumen or bitumen mixture of the roofing material.

After attainment of the lifetime and after the associated taking-down,the bituminous roof covering is melted, with that part of the linerand/or reinforcement whose melting point is below that or below theprocessing temperature of the bitumen or bitumen mixture melting away inthe hot liquid bitumen or bitumen mixture. Through a weight ratio of theliner or coating of 1/40, for example, it is possible to disregard theeffect of the melted liner or of the support on the quality of therecycled bitumen. A plastic such as polypropylene may even improve thebitumen quality.

Since the roofing material comprises (almost) exclusively liners havinga melting and/or processing temperature which are substantially equal toor lower (or even possibly, to a small extent, higher—but not more thanabout 20° C.) than those and/or than the processing temperature of thebitumen or bitumen mixture, it can be recycled. This takes place in asingle step, without any need for mechanical separation of the solidparts from the melted liquid bitumen.

The roof lining in accordance with the invention, furthermore, in asecond aspect of the invention, has the feature that a liner and/orreinforcement, more particularly strengthening, is formed exclusively oralmost exclusively of wires or loose fibers embedded into the bituminouslayer or layers.

In accordance with the feature of the roof lining according to theinvention, the fibers or wires consist of a plastic or of glass.

In accordance with a further feature of the roof lining according to theinvention, the liner and/or reinforcement, more particularlystrengthening, consists exclusively or almost exclusively of a materialhaving a melting temperature which is the same as or higher than that ofthe bituminous stratum or strata.

Furthermore, in accordance with a further feature of the roof liningaccording to the invention, the liner and/or reinforcement, moreparticularly strengthening, consists exclusively or almost exclusivelyof a material having a processing temperature which is the same as orhigher than that of the bituminous stratum or strata.

In accordance with another feature of the roof lining according to theinvention, the liner and/or reinforcement, more particularlystrengthening, consists exclusively or almost exclusively of a materialhaving a melting temperature not only above 100° C. but also, inparticular, above 150° C.

In accordance with another feature of the roof lining according to theinvention, the liner and/or reinforcement, more particularlystrengthening, consists exclusively or almost exclusively of a materialhaving a melting temperature above 200° C.

In accordance with a further feature of the roof lining according to theinvention, the fibers and wires consist, among others, of aramide,polyester, or glass, or other fibers having a melting and processingtemperature which is the same as or higher than that of the bituminousstratum or strata.

In accordance with yet a further feature of the roof lining according tothe invention, the amount of fibers is 0.01 weight percent to 25 weightpercent.

In accordance with yet a further feature of the roof lining according tothe invention, the amount of the fibers is 0.1 weight percent to 5weight percent.

In accordance with a further feature of the roof lining according to theinvention, the length of the fibers or wires is 0.1 mm to 500 mm, and inaccordance with yet a further feature they have a diameter of 0.001 mmto 5 mm.

The length of the fibers or wires, in accordance with yet a furtherfeature of the roof lining according to the invention, is 1 mm to 50 mm.This length is in particular 5 mm, and in accordance with yet a furtherfeature they have a diameter of 0.004 mm to 2 mm and in particular adiameter of 0.014 mm.

In accordance with the invention, the liner and/or reinforcement, moreparticularly strengthening, consists exclusively or almost exclusivelyof one or more of the abovementioned materials. After it has beenstripped off, the bituminous roof lining is melted. The fibers or wireshere remain scattered within the melted bitumen or the bitumen mixture.The influence of the fibers or wires on the quality of the recycledbitumen can be disregarded. Since exclusively or almost exclusivelyloose fibers or wires are incorporated in the roof lining material, saidmaterial can be recycled in one step, without any need to carry outmechanical deposition of the solid parts of the melted bitumen.

On the roofs, the quality of the bitumen mixture of the roof coveringexperiences virtually no change within a period of 25 years, and afterrecycling may be considered as new or as reusable for the new bituminousroof lining. The result, so to speak, is a sustainable “cradle tocradle” product with no CO₂ problem.

In a first variant, the invention extends to a series of embodiments asfollows:

1. In a first aspect of an embodiment, the roofing material is one whichis formed by one or more bituminous layers and which also, with a linerand/or the reinforcement, consists (almost) exclusively of a materialfor which the melting point corresponds to or is below that of thebituminous layer(s).

2. This roofing material is one which, corresponding to embodiment 1,possesses the feature that the liner and/or reinforcement consists(almost) exclusively of a material having a processing temperature whichcorresponds to or is below that of the bituminous layer(s).

3. This roofing material is one which, corresponding to embodiment 1 and2, possesses the feature that the liner and/or reinforcement consists(almost) exclusively of a material having a melting temperature which isbetween 50° C. and 220° C. or more precisely between 100° C. and 200° C.

4. This roofing material is one which, corresponding to theaforementioned embodiment, possesses the feature that the liner and/orreinforcement consists (almost) exclusively of a material whoseprocessing temperature is below 180° C.

5. This roofing material is one which, corresponding to theaforementioned embodiment, possesses the feature that the reinforcementis formed by fibers and/or wires.

6. This roofing material is one which, corresponding to theaforementioned embodiment, possesses the feature that the liner and/orreinforcement is formed of one or more plastics, such as, for instance,polypropylene, polyamide (nylon), polyethene, polyethylene, polyvinylchloride (PVC), polyacrylonitrile (acrylic), ethylene-vinyl acetate(EVA), or a similar material.

In a further variant, the invention extends to a series of embodimentsas follows:

1. In a further aspect of the embodiment, the roofing material is onewhich is formed by one or more bituminous layers and which is alsoprovided with a liner and/or reinforcement and which possesses thefeature that the liner and/or reinforcement consists (almost)exclusively of a material having a melting temperature which is higherthan the melting temperature of the bituminous layer or layers, andwhich corresponds largely to the processing temperature of thebituminous layer or layers.

2. This roofing material is one, corresponding to the mandates ofembodiment 1, with the feature that the liner and/or reinforcementconsists (almost) exclusively of a material having a melting temperaturewhich corresponds to or is below the melting temperature of thebituminous layer or layers.

3. This roofing material is one, corresponding to the mandates ofembodiment 1 and 2, with the feature that the liner and/or reinforcementconsists (almost) exclusively of a material having a melting temperaturewhich is between 50° C. and 220° C., more precisely between 100° C. and200° C.

4. This roofing material is one, corresponding to the mandates of thepreceding embodiment, with the feature that the liner and/orreinforcement consists (almost) exclusively of a material having amelting temperature below 180° C.

5. This roofing material is one, corresponding to the mandates of thepreceding embodiments, with the feature that the reinforcement is formedby fibers and/or wires.

6. This roofing material is one, corresponding to the mandates of thepreceding embodiments, with the feature that the liner and/orreinforcement consists by one or more kinds of the plasticspolypropylene, polyamide (nylon), polyethene, polyethylene, polyvinylchloride (PVC), polyacrylonitrile (acrylic), ethylene-vinyl acetate(EVA) and such materials.

In a second variant, the invention extends to a series of embodiments asfollows:

1. In a second aspect of the embodiment, a roof lining is one composedof one or more bituminous strata and additionally having a liner and/orreinforcement, more particularly strengthening, with the feature thatthis liner and/or reinforcement, more particularly strengthening, isformed exclusively or almost exclusively of wires or loose fibersembedded into a bituminous stratum/in bituminous strata, equipped.

2. A roof lining according to embodiment 1, with the feature that theliner and/or reinforcement, more particularly strengthening, consistsexclusively or almost exclusively of a material having a meltingtemperature above 100° C. and, further, in particular above 150° C.

3. A roof lining according to embodiment 1 and 2, with the feature thatthe liner and/or reinforcement, more particularly strengthening,consists exclusively or almost exclusively of a material having amelting temperature above 200° C.

4. A roof lining according to embodiments 1, 2, and 3, with the featurethat the fibers or wires consist of a plastic or glass.

5. A roof lining according to any of the aforementioned embodiments,with the feature that the fibers or wires consist of aramide, polyester,or glass, or other fibers or wires, with a melting point above theprocessing temperature of the bitumen or bitumen mixture.

6. A roof lining according to any of the aforementioned embodiments,with the feature that the amount of fibers is 0.1 weight percent to 5weight percent.

7. A roof lining according to any of the aforementioned embodiments,with the feature that the amount of fibers is 0.1 weight percent to 5weight percent.

8. A roof lining according to any of the aforementioned embodiments,with the feature that the length of the fibers or wires is 0.1 mm to 500mm.

9. A roof lining according to any of the aforementioned embodiments,with the feature that the length of the fibers or wires is 1 mm to 50 mmand in particular 5 mm.

10. A roof lining according to any of the aforementioned embodiments,with the feature that the diameter of the fibers or wires is 0.001 mm to5 mm.

11. A roof lining according to any of the aforementioned embodiments,with the feature that the diameter of the fibers or wires is 0.004 mm to2 mm and in particular 0.014 mm.

Working examples of the invention are now described below, withreference to the drawing, in comparison to the prior art, which in partis likewise depicted. The drawing is not necessarily intended to depictthe working example to scale; instead, where useful for elucidation, thedrawing has been executed in diagrammatic and/or slightly distortedform. In respect of supplements to the teachings which can be discerneddirectly from the drawing, reference is made to the relevant prior art.It should be borne in mind here that diverse modifications andamendments concerning the form and detail of an embodiment may be madewithout departing from the general concept of the invention. Thefeatures of the invention that are disclosed in the description, in thedrawing, and in the claims may, not only individually but also in anydesired combination, be essential for the development of the invention.Moreover, the scope of the invention encompasses all combinations of atleast two of the features disclosed in the drawing, the descriptionand/or the claims. The general concept of the invention is not confinedto the exact form or the detail of the preferred embodiments that areshown and described below, or confined to any subject matter that wouldbe restricted in comparison to the subject matter claimed in the claims.In the case of stated ranges of dimensioning, the intention is thatvalues lying within the stated limits should also be disclosed aslimiting values and should be capable of being claimed and used at will.Further advantages, features, and details of the invention will becomeapparent from the description below of the preferred embodiments, andalso with reference to the drawing;

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1: a diagram of an apparatus and a method for producing a roofingmaterial according to a first embodiment;

FIG. 2: a diagram of an apparatus and a method for producing a roofingmaterial according to a second embodiment;

FIG. 3: a diagram of an apparatus and a method for producing a roofingmaterial according to a third embodiment;

FIG. 4: a diagram of an apparatus and a method for producing a roofingmaterial according to a fourth embodiment;

FIG. 5: a diagram of an apparatus and a method for producing a roofingmaterial according to a fifth embodiment.

DETAILED DESCRIPTION

The apparatus and the production method according to FIG. 1 has:

a bitumen supply 11, an upper calibrating roller 12, a lower calibratingroller 13, at 14 a support belt or support lattice of bitumen-freematerial, such as silicone or Teflon, a bitumen collecting tank 15, areverse roller 16, a nonwoven or woven fabric liner 17, a bituminousroofing membrane 18, a cooling air supply 19.

The apparatus and the production method according to FIG. 2 has:

a bitumen supply 21, an upper calibrating roller 22, a lower calibratingroller 23, at 24 and 26 a support roller and a positioning roller,respectively, a bitumen collecting tank 25, a nonwoven or woven fabricliner 27, a bituminous roofing membrane 28, and a cooling air supply 29.

The apparatus and production method according to FIG. 3 has:

a bitumen coating tank 31, a support belt 32, with drive, a liner 33,and a calibration device 34.

The apparatus and the production method according to FIG. 4 has:

a bitumen supply 41.1 for the bottom edge of the roofing membrane, abitumen supply 41.2 for the top edge of the roofing membrane, anintroduction unit 43 for the liner 47, a straight roofing membrane 48with the liner 47 and outer strata of bitumen, and a support belt 44.

The apparatus and the production method according to FIG. 5 has:

a bitumen supply 51, with bitumen mixture 1 to be supplied and withreinforcing fibers 2 to be supplied, and a support belt 54.

In general it has proved advantageous for the melting temperature of thesupport (e.g., 150° C.) to be above the melting temperature of thebitumen layer (e.g., 120° C.) and below the processing temperature(e.g., 180° C.) of the bitumen layer. In a modification, the meltingtemperature of the support may also be at the processing temperature(e.g., 180° C.) of the bitumen layer or within a range which is limitedto a temperature of not more than 20° C. above the processingtemperature of the bitumen layer.

In the case of the fibers, the melting temperature of the fibers oughtalways to be higher than the processing temperature of the bitumen.

1-29. (canceled)
 30. A roofing material comprising one or morebituminous layers of a bitumen mixture that becomes liquid at aprocessing temperature deposited on a liner, the liner consistsexclusively of a material having a melting temperature which is higherthan the processing temperature of the bituminous layer or layers, butis not more than 20° C. higher, and/or which corresponds largely to theprocessing temperature of the bituminous layer or layers, the linerconsists of a woven fabric and consists exclusively of a material havinga melting temperature which is between 150° C. and 200° C., and/or areinforcement is formed as strengthening by fibers and/or wires with amelting point above the processing temperature of the bitumen mixture.31. The roofing material as claimed in claim 30, wherein the linerconsists exclusively of a material having a melting temperature below180° C.
 32. The roofing material as claimed in claim 30, wherein theliner is selected from the group consisting of polypropylene, polyamide,poylethene, polyethylene, polyvinyl chloride, polyacrylonitrile,ethylene-vinyl acetate, and mixtures thereof.
 33. The roofing materialas claimed in claim 30, wherein the fibers and/or wires are one ofplastic and glass.
 34. The roofing material as claimed in claim 30,wherein the fibers and/or wires are formed of one of aramide andpolyester.
 35. The roofing material as claimed in claim 30, wherein thefibers and/or wires are present in an amount of 0.1 weight percent to 5weight percent.
 36. The roofing material as claimed in claim 35, whereinthe fibers and/or wires have a length of 0.1 mm to 500 mm.
 37. Theroofing material as claimed in claim 35, wherein the fibers and/or wireshave a length of 1 mm to 50 mm.
 38. The roofing material as claimed inclaim 35, wherein the fibers and/or wires have a length of 5 mm.
 39. Theroofing material as claimed in claim 36, wherein the fibers and/or wireshave a diameter of 0.001 mm to 5 mm.
 40. The roofing material as claimedin claim 37, wherein the fibers and/or wires have a diameter of 0.004 mmto 2 mm.
 41. The roofing material as claimed in claim 37, wherein thefibers and/or wires have a diameter of 0.014 mm.
 42. A roofing materialcomposed of one or more bituminous layers of a bitumen mixture thatbecome liquid at the processing temperature, and further equipped with areinforcement as strengthening, wherein the reinforcement is formedexclusively of wires and/or loose fibers embedded into the bituminouslayer or the in bituminous layers, the reinforcement consistingexclusively of a material having a melting temperature which is higherthan the processing temperature of the bituminous layer or layers and/orwhich corresponds largely to the processing temperature of thebituminous layer or layers, the reinforcement consisting exclusively ofa material having a melting temperature above 150° C.
 43. The roofingmaterial as claimed in claim 42, wherein the reinforcement consistsexclusively of a material having a melting temperature above 200° C. 44.The roofing material as claimed in claim 43, wherein the fibers and/orwires consist of a plastic or glass.
 45. The roofing material as claimedin claim 43, wherein the fibers and/or wires are formed of one ofaramide and polyester.
 46. The roofing material as claimed in claim 44,wherein the fibers and/or wires are present in an amount of 0.1 weightpercent to 5 weight percent.
 47. The roofing material as claimed inclaim 42, wherein the fibers and/or wires have a length of 0.1 mm to 500mm.
 48. The roofing material as claimed in claim 46, wherein the fibersand/or wires have a length of 1 mm to 50 mm.
 49. The roofing material asclaimed in claim 46, wherein the fibers and/or wires have a length of 5mm.
 50. The roofing material as claimed in claim 47, wherein the fibersand/or wires have a diameter of 0.001 mm to 5 mm.
 51. The roofingmaterial as claimed in claim 48, wherein the fibers and/or wires have adiameter of 0.004 mm to 2 mm.
 52. The roofing material according toclaim 50, wherein the fibers and/or wires have a diameter of 0.014 mm.53. The roofing material as claimed in claim 41, wherein the fibers areselected from the group consisting of synthetic fibers, natural mineralfibers, stone, basalt, glass, and slags.
 54. A method for producing aroofing material which is formed by one or more bituminous layers of abitumen mixture, the bitumen mixture of the one or more bituminouslayers being liquefied at a processing temperature and deposited on aliner, wherein the liner is provided exclusively consisting of amaterial having a melting temperature which is higher than theprocessing temperature of the bituminous layer or layers, but not morethan 20° C. higher, and/or which corresponds largely to the processingtemperature of the bituminous layer or layers, comprising providing aliner consisting of a woven fabric exclusively consisting of a materialhaving a melting temperature which is between 150° C. and 200° C. 55.The production method as claimed in claim 54, including forming areinforcement as strengthening by fibers and/or wires with a meltingpoint above the processing temperature of the bitumen mixture.
 56. Theproduction method as claimed in claim 55, including recycling of theroofing material, wherein after having reached the roofing materiallifetime, the roofing material is melted to form a hot liquid bitumenmixture, where at least that part of the liner and/or reinforcementwhose melting point is below the processing temperature of the bitumenmixture of the one or more bituminous layers melts away in the hotliquid bitumen mixture.
 57. The production method as claimed in claim56, wherein the recycling takes place in a single melting step, withoutany need for mechanical separation of solid parts from the melted,liquid bitumen mixture.